RF Outlet to Light Switch Hack 2.0

About two weeks ago this project stopped working.  More specifically the lights of the room were off and when I went to turn them on only the LED switch lit up but no typical "click" from the relay to turn on the overhead lights.  I cycled the button a few times and once that didn't work I quickly shut off the breaker and removed the malfunctioning switch.  It did not trip the breaker so I suspect maybe the relay is bad.  I have yet to open the enclosure to troubleshoot since I have to fabricate a simple bench set-up to go through all the modes of failure.  My original style RF light switch hack is still working in a few other rooms for almost two years now without a single issue.

I will post my findings once I can dedicate time to the root cause.

2/21/2017: I completed the instructions to disassemble the RF outlet and the wires that need to be desoldered and then replaced with new wiring that will be connected later.

2/2/2017: My new Monoprice Select Mini (MPSM) has really brought me back to loving 3D printing again. I always loved being able to make custom things however my older Printrbot Plus had become a chore of never ending maintenance and I quickly stopped using it when I spent more time getting it working than printing. With my MPSM I was printing right out of the box and have never looked back.

My original idea for this project was to take the use of a 3D printer off the table since wanted to have a largest audience as possible. This presented early challenges when the off the shelf enclosure (potting box) I found wasn't making integration as easy as planned. I have decided I will still create this project with a non-3D printer option however the implementation will most likely be for single gang light switches, not the end of the world but not meeting my original goal.

This specific project I have decided to transition to a 3D printed enclosure after I designed and printed one up in a couple of hours and everything just worked.

My first cut design turned out a little bigger than expected and after further investigation it doesn't look like it would work in a multi-gang outlet. I will have to remove some depth from the enclosure also since it was pretty tight in my outlet box (but no more snug if I was installing a wifi switch or any other large housing device).

Jan 20th: I finalized my wiring a few days ago. Here is a video of the circuit in action.

Tonight I put together a powerpoint wiring diagram to best show how everything will need to be connected. My goal is to get the circuit board from the outlet in a consumable format in Fritzing.

Jan 15th: Project costs is something I am always trying to always reduce. Currently I have not found UL1015 wire in short lengths and only in 100' spools. Also having wires in different colors always make wiring the project easier is not a requirement. I originally spent $75 for three(3) spools of the UL1015 wire (16awg red and black, 18awg white) so that everything would be color coded and make wiring into my home wiring straight forward. In high sight I could have gotten away with just one(1) spool of 16awg and then just had to clearly label each wire.

Another area would be to eliminate the LED switch breakout since it would get another $1-2 and just makes wiring everything up a little easier. Near term I plan to keep the breakout but it will be something I mention as being optional.

Jan 12, 2017: The goal of this project is to use simple tools and skills to build. I don't want to limit others from building this project due to lack of a 3D printer or other expensive equipment. This will be a bit difficult since I have not found a clean cut off the shelf enclosure to house the electronics in AND still fit inside an electrical gang box. I have a great concept for a 3D printed enclosure but for the time being I will shelf that idea until I can fully develop this project.

Along with this project please follow my daily log on Hackday.io of everything I am working on this year.